How to Rewind & Repair a 3 Phase Motorcycle ATV UTV Powersports Stator Yourself 

Hello... Good day... I always notice about replies from channel owner to the subscribers quiries in the comment section.... If these are available then it is a good channel (This is what I assume)... The best thing about you is that you have replied almost all of the comments..... Regards....

RU-vid is awesome. Thanks for sharing this video. Very informative, and now I know how to wind a stator!!

I have two older suzuki 's..and both have dead stators. .Thank You for this informative video!!!

fantastic video and explanation.

IM AT 2:33 in your video and Im getting excited about your project. how neat! I am working on a 1979 honda xl250s and I am changing it from 6 to 12 volts and changing the headlight coil to DC closed circuit with no chassis ground. and leaving the ignition coil as is (AC chassis ground CDI that is shared with the DC tail,turn signal, horn stator coil that charges 12V battery) I am running 12 volt LED headlight through the headlight AC stator coil that is being disconnected from chassis ground and made into a 12V regulated/rectified circuit and I got a big capacitor to stabilize the current flicker, I have to disconnect the high beam indicator light from chassis ground, and the headlight chassis ground is disconnected as well and ran in series together to the headlight stator coil so that it is isolated from the DC charging coil and the AC ignition shared chassis coil. I hope it works good. I built a grizzly g0704 cnc milling machine and a g0602 cnc lathe both use centroid acorn cnc controllers and have 1.8kw servo spindle motors with 10,000 pulse per rev encoders for rigit tapping on mill and rigid tapping on lathe and designed an 8 tool auto tool changer turret for the lathe. so anyway, I want to design a new stator for the 19-81 honda xl250 and xl500 that uses up all the space inside to maximize the output for the conversion to LED lights to make it safer for people to ride at night. I want to program the lathe to wind the field windings perfectly by measuring the thickness of the winding being used and writing a program to move distance per revolution to wind perfect coils fast. I can use the cnc mill to cut out the plates are those called armature plates? not sure but I use fusion 360 to do all my CAD so I could design it really well before even making one part. well I just wanted to share that with you since your winding your own coil, and see what you have to say about that. thanks have a great day, now back to watching your video.

My dad rewound a gs750 suzuki alternator in 1985 when a new replacement cost 1 .months wages..sealed with areldite worked great

awesome video, would like to try it one day maybe, good job

That's a great video dude! Thanks for inspiring me. I don't need to rewind yet, but if I do, I know I'll use your video again. Keep up the good work!

Very good information. Thanks a lot ❤️

Excellent video. Thanks

yup a Delta, I think u r a motor winder, So u know the work is done in the COILS each coil being good for so many ampere-turns. a coil can be bad but not grounded to frame, just by the enamel getting burned off and touching each other, then u get less voltage built up in each coil and say the wire is good for 22 amps for a single phase stator like on a Harley Sporty, then less volts X the available amps gives less watts of power. I did a stator a while ago, it was a Y . wind 1 bobbin, skip 2 bobbins. so if u have 15 poles or bobbins each phase has 5 poles. I marked the phase of each bobbin start an finish, wired the 3 starts together. this is why on motors u have A and AA, A being the start of the winding AA being the end, and F and FF.Great video. I went to a motor rewind shop to buy magnet wire.

That's cool as hell. Thanks man!!

I bought a new stator (used off ebay), but I actually wanted to rewind the broken one. The old stator is still in the wardrobe, and armed with this info I'm enthusiastic to get winding. Thanks.

I have an inverter generator that has a burned coil. I can’t find a replacement so I’m considering rewinding it. Thank you for this help

Excellent video. Thanks. Just wish you showed you wrapping the wiring around.

Gracias amiguito saludos desde México execelente video

Hi, thanks for the video I really enjoyed watching. My question is when you rewind the stator for more amperage output you would use a thicker wire. How does this effect stator output voltage ? As in producing more or less AC volts

When you bake the epoxy in the oven, will the heat affect the wires you've soldered onto the copper winding at all? Could these wires be soldered after applying the epoxy? Thanks for taking the time to make this video btw. You explained and showed it all clearly. I was trying to get my head round an Instructable, but this is much better.

Thanks so much bro for the tutorial... Helps alot!!! I wanted to find out, if the resin powder coat (green) is cleaned off - thus revealing a bare metal stator, is it necessary to reinsulate it? If so what material can we use to do this? Thanks a mil! 🤙🏼

I'm trying to rewire my wind turbine stator and this video has been the most informative of all I've seen because you explain the wiring sequence however you didn't illustrate that for us only showing the end result which doesn't illustrate the end to end winding sequence. Ifg all the ends were put together wouldn't that leave you with two wire instead of three?

Thanks for an informative video! I am attempting to rewind a pulser and exciter coil for a JS550 jet ski. Do you know if winding direction matters in this situation?

Excellent video! i have a question thought. If the final resin is so powerful that makes the coils lasts forever. Why the stock resin allows the coils get damaged on the first place? thanks!!

Very informative video Q&E Evin. . I am wondering what the insulation wire that you are using. Does the insulation degrade with the oven curing process of the epoxy ?? How about the increased wire size, do you get more amps charging from the GXR stator ??? Nice job fella. Look forward to more great videos from you SIr. Good day and Peace too. vf

Was there a name for the 3 white wires you used,?? Cheers great vid 👍

How easy is it to replce the wires going from the stator to the main loom, seems to me you remove the loom wires from the terminals they are soldered to on the stator and solder in new wires.

Need a little help rewinding a stator out of a Force outboard. 3 phase stator, one of the phases uses thicker wire, the other 2 phases use 1 mm wire, hair thin. It is one of these two thin wired phases that needs to be rewinded, as it burned between 2 of the coils. I removed the wire and repaired the burned insulation, bought 50 meters of 1 mm wire, but it came in 5 rolls of 10 meters, not enough to wind it uninterrupted. I wander if each of the 5 coils I must rewind can be done with a roll of wire, then conect it to the next coil by soldering in between coils. Another issue is that I could not do the loop count, as the thin wire came out in chunks together with the epoxy. I have the other thin wired phase intact, with 735 ohms of resistance across the the leads. Thanks for your input

You under stand this more than I do. I have a 1986 Honda cmx250 I can not find a new or used stator for all the wires at the cover are hard and have been tinkered with before I got the bike. Would you be willing to rewind mine. Of coarse paying you to rebuild it. Maybe I just need to resolder new wires from the stator? They are very hard and brittle and wire is exposed thru the wire jacket on all of the wires

Hi, I've got a 3 phase stator from a KTM 690 and when I removed it for visual inspection I noticed that a little corner of the dieletric green coating came slightly off in 3 of the core ''branches'... Do you think is that a problem? Is there a short circuit if for example the green coating comes off and the copper wire touches the ''branches/arms'' of the core? thanks a lot PS: dont the wires melt when you cure it in the oven? :O

hi sir why my stator of yamaha r1 when i test in ohms its only 0 no resistance, it means busted or shorted???thank you for your responce

thanks bro

So I have an eBay stator in my gsxr and it doesn’t charge at idle only high rpm pretty sure it’s wound to “ wye” can I simply just grab the three starts separate them and connect them in series or do I have to re wind the entire stator?

In star connection do we have to connect the neutral to the body or do we have to isolate it

Eu vou escrever em português mesmo - essa é a melhor explicação que eu achei no RU-vid parabéns

Does the winding direction makes any difference, as long as all are in the same direction and properly connected? I think I winded mine in the opposed direction of oem. Best regards.

Do you know approximately how much of copper wire (in lenght) is needed for this job?

Awesome video. I have a 17 KTM 350 XCF Which has a four wire stator. The factory output is 30w. I want to increase the output as I am making it street legal with the required lighting. Are there any resources you could steer me towards that will help me accomplish this? It differed from this video as it appears to have two circuits with four wires on the harness total. One is for the the battery and one for the ignition circuit. Also when rewinding for more power what are the limiting factors? I would imagine at a certain point the regulator/rectifier would need to be up sized to match. Alot of aftermarket direct fits for this bike come at 90w max roughly and say they direct swap with no other upgrades. I imagine this is the max wattage the stock regulator/ rectifier can handle. Any assistance or where to find published information is appreciated. Seems easy enough to do and worth saving 200 dollars. Thanks Pat

what did u use for that green insulation layer? thanks

I have my stator fail. Only one phase. What can cause such a failure? Do you think it can be fixed if I soak it into resin or something? I have measured between phases and they all are connected to each other and no one is grounded to earth. I just don't get enough voltage in one phase. Any input apreeciated.

Which meterial armature are made,the green part

Great information, can you tell if thickness and rounds of wire will effect?

You left out the part where you connected each of the wires together from a b and c. I would have liked to have seen you do that

Great video!. Super informative!. I recently got a CDI stator off of e-bay that looked to be brand new, but sadly when I Ohms tested it using the red and red/white wires it came up short. So I was wondering, have you ever had it where all you had to do was replace the wire leads, and the stator windings were just fine?. I was thinking of just carefully peeling back the red and red/white wires to the copper and de-soldering them, and running new wire to try and see if that would work?. Just curious if that is something you ever do, rather than rewinding the whole thing?. I have done a lot of soldering and electrical work before, but no stators yet, so I figured no harm in asking right?. Anyways thanks for the awesome video!. - Adam

What is that called the green insulator in the core?

better to make a silicone shell that clamps the coils when done. easier disassemble.

Where did you get your copper wires from?

How thick was that magnet wire? I mean the diameter of the wire.. I wanna try it myself too thanks

So in this application: the individual coils are isolated from one another in the air gap been each bobbin correct? But when shifting between bobbins near their base it's acceptable for the different phases to touch each other and the frame? I only ask because I'm my mind I'd imagined all of these components isolated from one another. Maybe the coils are normal to touch between bobbins but they're meant to be isolated from the core by a small gap? Hard to tell. I'm merely a former mechanic, can't recall testing details, and my repair generally stops once the diagnosis suggests the stator assembly and one is reordered. In my mind the connections were simply that which was shown in the Delta diagram. 3 individual phases with some resistance in each phase, testing wire to wire, and if I'm remembering right isolation from the base and "ground" of the bike. My memory fails me but I think that was the average testing procedure. So if I'm thinking right, the coils are isolated from the frame? Crossing phases between bobbins at the base is normal but crossing higher up them is bad? I guess I'm just wondering what isolation is required and where is it not required. Just curious mostly. Probably have 200 pounds of old stators laying around. Never thought to question the voodoo inside beyond passing or failing the resistance or output tests in each unit's manual. I'm nearly certain that it probably varies with scheme but just wondered if you had any insight before I dive farther into an already long toilet break research study on a task I'll likely never perform. I enjoy learning new things. Thanks for the video

What will happen if you go anticlockwise when doing the coil?

How to wind 6core 3 phase coil for old royal enfield bullet just give me an idea bro

Hi ... How do you get your pole wiring so tight? ... Really struggling with getting this right

How much is it that you charge to rewind stator on snowmobile

is it ok to use another type of wire? size or color.

Would you give out some links for the epoxy ?

A few pointers...... Thoroughly degrease first, ultrasonic bath recommended. 1) Repairing flaked off insulator, JB Weld does a good job. 2) *Must* use high temperature enamelled wire which has to be scraped for soldering. 3) After winding the assemblage should be vacuum impregnated with varnish specifically for the purpose, then baked. You can make a vacuum chamber with the input of a compressor. Sometimes you can get away with laying slow-set, high temp epoxy on the windings as you go but it's messy. 4) The wire should be drawn from a free-rotating bobbin to avoid a twist with every turn. 5) These winds are relatively easy so by all means go for it yourself. If your first attempt doesn't work out try again. But hand winding wave-wound (as car type or BMW, Moto Guzzi etc) is *extraordinarily* difficult. It can be done but not recommended unless you have a lot of time and a lathe to make up fancy formers and extreme ability / cussedness / patience / inventiveness / etc.

Bro can you help me to wind 6core 3phase coil for old enfield bullet

My stator has no epoxy or coating of any kind on it. Is that normal?

Can I send you my stator ? How much do you charge to fix it it came of a 05 Suzuki king quad 700 I’m not actually sure what’s wrong with it

Do you have to use epoxy or is that an extra step to make it last? Because I don’t wanna do it... lol 😂

If the wire is 1.15mm, can we put a 1,10 mm wire. Won't it be dangerous?

interesting

Surely this stator will not work? powder coat is damaged, if windings contact centre frame, I would expect it to not work, it's insulated for a reason.., is it not?

If the stator is wound with #16 gage and you go to #18 you reduce the current capacity.

why , only is 15 pole , 3 phase ? i don't know . i think it must 16 or 18 pole .

Bullet proof huh. My Ricks blew 3 weeks in. My Chinese is 5000 miles and running

Olá meu amigo! Pode me ajudar?

Why do you epoxy seal. While it protects wires from cracking. This doesn’t help cooling especially with oil. Most stock oem stators dont have any epoxy. And last thousands of miles.

You lost me at grind off the insulation… I thought the copper wire was bare?

why do you keep skipping the most important parts?